AR01.30-P-5800PV Remove/Install Cylinder Head
Remove/install cylinder head
Shown On Engine 112 In Model 203, Part 1:
Shown On Engine 112 In Model 203, Part 2:
DANGER:
- Lethal injuries are possible if vehicle slips off of lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.
CAUTION: See notes on self-locking nuts and bolts
DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead add batteries.
- No fire, sparks, open flames or smoking. Wear add protection gloves, clothes and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect ground cable of battery.
CAUTION: Model 209, 211: Do not connect quiescent current retention unit, otherwise damages can occur in the control modules.
2 Remove engine compartment paneling.
DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection.
3 Drain coolant.
NOTE: At radiator.
4.1 Remove engine trim panel with integrated air cleaner (4).
- Not Model 203.065/265
NOTE: The air cleaner is integrated in the engine cover. Remove engine cover or air cleaner by lifting vertically up and off the cylinder head covers.
4.2 Remove air cleaner housing
5 Remove fan shroud with electric fan (2)
- Not Model 211.061/065/070
6 Attach guard plate for radiator/condenser.
7 Remove hot film mass air flow sensor (B2/5)
DANGER:
- Risk of explosion if Ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.
- Fire, sparks, open flames or smoking forbidden. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.
8 Disconnect fuel line at fuel rail.
NOTE:
- Release fuel pressure through service valve!
- Collect fuel!
9 Remove right ignition coils (8), left ignition coils (10).
10 Remove right cylinder head cover (7), left cylinder head cover.
11 Remove air pump.
12 Remove intake manifold (13).
CAUTION: Installation: On vehicles with engine damage, the intake manifold (13) must be examined for swarf before being installed and any swarf present must be removed, otherwise it could lead to a renewed engine damage.
NOTE: The intake manifold system must not be disassembled.
13 Remove camshaft position sensor (L5/1)
NOTE: Only necessary if the right cylinder head is removed.
14 Remove poly V-belt (3).
NOTE: Installation:Lock tensioning device with a drift or pin (diameter 5 mm).
15 Remove compressor.
16 Remove coolant line (15) from left cylinder head (22) at bulkhead.
NOTE:
- Use a screwdriver to lock circlip in knurled marking, detach coolant hose.
- Installation: Move circlip to basic position before attaching cooling water hose.
17 Disconnect exhaust system from exhaust manifold.
CAUTION: Installation: On vehicles with engine damage it is necessary to inspect the exhaust system for swarf before installing it and to remove any swarf otherwise this might result in damage to the catalytic converter system.
18 Position crankshaft to 0 degrees after ignition TDC of cylinder.
NOTE:
- Engine must not be cranked backwards.
- Rotate engine at crankshaft in direction of rotation until 40 degrees marking on belt pulley/vibration damper is aligned with marking on timing case cover. The grooves on the camshafts must be pointing toward the inner V.
19 Lock camshafts with locating plates.
20 Unscrew bolts from oil filter housing with oil-water heat exchanger (18).
21 Remove chain tensioner (12).
NOTE: On alternator (G2) unscrew top bolt, slacken lower bolt. Swing back alternator (G2).
22 Unbolt camshaft sprockets (16).
CAUTION: When the camshaft sprockets (16) have been removed, the engine must no longer be cranked as otherwise the timing chain can jam.
NOTE:
- Right camshaft sprocket:
- Tighten timing chain with tie strap onto camshaft sprocket.
- Left camshaft sprocket:
- Identify camshaft sprocket to timing chain and remove camshaft sprocket. It is not possible for the timing chain to jump across at the crankshaft and balancing shaft.
- Installation: Inspect basic position of camshafts, If necessary after checking, Set the basic position of camshafts.
23 Remove camshaft bearing bridges (17).
24 Unscrew bolts of cylinder head -> Stiming case cover (20).
25 Loosen and remove the cylinder head bolts (21) in stages
CAUTION:
- Slacken cylinder head bolts (21) of cooled off engine according to loosening schema, because the elastic surface of the cylinder head bolts (21) is exceeded due to the additional torque influence.
- Installation: Observe tightening pattern and tightening instructions of cylinder head bolts (21), so that a delay of the cylinder head does not arise. Oil thread and bolt head contact surface of cylinder head bolts (21).
26 Remove cylinder head
CAUTION: Installation: On Engine 112 it is important to pay attention to porous points on left cylinder head (22) and right cylinder head (23). In order to avoid leakage, it is necessary to apply sealing compound on the left cylinder head gasket (24) and right cylinder head gasket (25) because of porous points.
NOTE:
- The sealant must be applied within 10 minutes.
- See Information on applying sealant to cylinder head gasket.
- See Information on cylinder head contact surface.
- See Information for assigning the cylinder head gaskets.
27 Check cylinder head bolts (21)
28 Clean sealing surfaces, inspect for cracks, shrink holes and flatness, clean threaded holes
NOTE:
- Pay attention to dowel sleeves (26) for locating the cylinder head.
- Sealing surfaces of crankcase and cylinder head are provided with an 0.8 mm thick silicone layer during series production. At the time of repair installation, silicone sealant is applied to the sealing area only in case of any shrink holes. The sealant must be applied within 10 minutes! Loctite sealing compound 5900.
29 Install in the reverse order.
DANGER:
- Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns.
- Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.
30 Run engine and inspect for leaks.
31 Bleed cooling system.
NOTE: Warm up the engine to normal operating temperature and fully open temperature regulator of heating (position "warm").
32 Inspect cooling system for leaks.
NOTE: Warm up engine to operating temperature and then inspect cooling system for leaks.
33 Perform basic programming.
34 Read out fault memory with STAR DIAGNOSIS and erase if necessary.